Fiber Blended Yarn Production via Liquid-Phase Gas Interlacing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fiber blended yarns and fabric cloths lack sufficient strength for applications in structural materials like automobiles, necessitating improved methods for fiber blending and impregnation to enhance mechanical properties.
Innovation Solution
The method involves blending thermoplastic resin fibers with reinforcing fibers using a gas in the presence of a liquid, with specific conditions such as limited moisture content, hydrophilicity, and organic material adhesion to achieve high strength and interface strength in the resulting molded bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber blending is performed in a dry atmosphere to suppress moisture adsorption, then damage to reinforcing fiber is reduced, but fiber blend rate and impregnation ability deteriorate
Solution Approach 1:
The invention changes the physical state parameter of the blending environment from dry atmosphere to liquid-phase immersion, fundamentally altering how fibers interact during blending. This parameter change allows simultaneous achievement of high fiber blend rate and maintained fiber strength, resolving the contradiction between preventing fiber damage and ensuring impregnation ability.
Solution Approach 2:
The invention introduces liquid as an intermediary medium between reinforcing fibers and thermoplastic resin fibers during the blending process. This liquid mediator facilitates fiber opening and mixing while preventing direct damage to reinforcing fibers, enabling both high fiber blend rate and high impregnation ability to coexist.
2Reliability
If fiber blend rate is increased to improve impregnation ability, then molding performance improves, but damage to reinforcing fiber increases
Solution Approach 1:
The liquid intermediary protects reinforcing fibers during the intense mixing process required to achieve high fiber blend rates. By providing a cushioning medium, the liquid allows aggressive blending actions without causing fiber breakage, thus simultaneously improving impregnation ability while maintaining fiber strength.
Solution Approach 2:
The invention changes the blending medium from gas (air) to liquid, fundamentally altering the mechanical interaction between fibers. This parameter change enables higher fiber blend rates to be achieved without the damaging effects observed in conventional dry blending processes.
3Quantity of substance
If reinforcing fiber is opened extensively to improve mixing, then fiber blend rate increases, but fiber strength decreases due to damage
Solution Approach 1:
The liquid intermediary enables extensive fiber opening and mixing by providing a protective environment. The liquid reduces direct fiber-to-fiber contact forces that cause damage, allowing the reinforcing fibers to be thoroughly opened and mixed with thermoplastic resin fibers while maintaining their structural integrity and strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in fiber-reinforced resin molded bodies with arbitrary shapes and excellent mechanical strength, suitable for structural applications.
Implementation Method 1
by performing fiber blending of the thermoplastic fiber and the reinforcing fiber using a gas in the presence of a liquid... the resulting molded bodies exhibit high strength and high interface strength
Implementation Method 2
the interlace method be a fluid disturbance method
Implementation Method 3
the reinforcing fiber comprise a hydrophilicity index of 8 degrees or more
Data Source
Figure 1~3
AI summary
[Problem to be solved] Methods for producing a fiber blended yarn, and a woven fabric or a knit fabric that allow producing fiber-reinforced resin molded bodies having arbitrary shapes and excellent strength are provided. [Solution] A method for producing a fiber blended yarn of the present invention is a method for producing a fiber blended yarn including at least a thermoplastic resin fiber and a reinforcing fiber, the method including the step of blending the thermoplastic resin fiber and the reinforcing fiber with an interlace method that uses a gas under the presence of a liquid. A fiber blended yarn of the invention is a fiber blended yarn including at least a thermoplastic resin fiber and a reinforcing fiber, the fiber blended yarn including at least two kinds of organic materials, and the at least two kinds of organic materials adhere to both the reinforcing fiber and the thermoplastic resin fiber. A method for producing a woven fabric or a knit fabric of the invention is a method for producing a woven fabric or a knit fabric including at least a thermoplastic resin and a reinforcing fiber, the method including weaving the reinforcing fiber that comprises a moisture ratio ranging from 0.1 to 5 mass %.